Method and means for securing a face frame to a box cabinet

ABSTRACT

A method of securing a face frame to a cabinet box whereby spring clamps clamp the face frame to the cabinet box during the gluing process. The method eliminates the need for nails, staples, pocket screws or the like. The spring clamp of the invention enables the face frame to be secured to the outer ends of the cabinet box.

CROSS REFERENCE TO RELATED APPLICATION

This is a Divisional Application of application Ser. No. 14/529,240filed Oct. 31, 2014, entitled METHOD AND MEANS FOR SECURING A FACE FRAMETO A BOX CABINET. Applicant hereby incorporates application Ser. No.14/529,240 filed on Oct. 31, 2014 entitled METHOD AND MEANS FOR SECURINGA FACE FRAME TO A BOX CABINET herein by reference thereto.

BACKGROUND OF THE INVENTION Field of the Invention

This invention relates to a method and means for securing a face frameto a cabinet box. More particularly, this invention relates to a methodand means for securing a face frame to a cabinet box without the use ofnails, staples, pocket screws, splines, biscuits, tongue and groove,dowels or bar clamps.

Description of the Related Art

Conventional face frame cabinets are comprised of a cabinet box orcarcass which may be a base cabinet, a wall cabinet or a tall cabinet.The typical cabinet has a horizontally disposed upper wall member havingan outer end, an inner end, a first end, a second end, an upper surfaceand a lower surface. The cabinet box also includes a vertically disposedfirst side wall member having an outer end, an inner end, an upper end,a lower end, an outer surface and an inner surface. The cabinet boxfurther includes a vertically disposed second side wall member having anouter end, an inner end, an upper end, a lower end, an outer surface andan inner surface. The cabinet box further includes a horizontallydisposed bottom wall member having an outer end, an inner end, a firstend, a second end, an upper surface and a lower surface.

The first end of the upper wall member is secured to the upper end ofthe first side wall member. The second end of the upper wall member issecured to the upper end of the second side wall member. The first endof the lower wall member is secured to the lower end of the first sidewall member. The second end of the lower wall member is secured to thelower end of the second side wall member.

In conventional face frame cabinets, a face frame is secured to theouter ends of the upper wall member, the first side wall member, thesecond side wall member and the lower wall member. In some prior artmethods, the face frame is secured to the cabinet box by nails extendingthrough the face frame into the outer ends of the wall members of thecabinet box. In that situation, the nail holes must be filled with woodputty or the like in an effort to conceal the nail holes. Sometimes, thewood putty will have a different appearance than the face frame. Inother installations, nails are toe-nailed into the face frame and thewall members of the cabinet box. In other installations, pocket screwsare extended through the outer ends of the wall members into the faceframe. All of the above described methods of securing a face frame to acabinet box result in labor intensive steps and efforts to conceal thefastening elements.

SUMMARY OF THE INVENTION

This Summary is provided to introduce a selection of concepts in asimplified form that are further described below in the DetailedDescription. This Summary is not intended to identify key aspects oressential aspects of the claimed subject matter. Moreover, this Summaryis not intended for use as an aid in determining the scope of theclaimed subject matter.

The invention relates to two different methods of securing a face frameto a cabinet box or carcass. Both of the methods require the use of aconventional spring clamp which has been modified somewhat.

The spring clamp which is used in both of the disclosed methods issimilar to a spring clamp marketed by Menard, Inc. having a productnumber 249-1316. The spring clamp of Menard, Inc. is modified somewhatto enable the spring clamp to be used to clamp a face frame to a cabinetbox or carcass. The spring clamp of this invention includes an elongatedand generally slightly curved first lever arm having a handle portion atone end thereof and a clamping portion at the other end thereof. Thefirst lever arm terminates in a clamping jaw with the clamping jawnormally having a pad or sleeve mounted thereon. The handle portion ofthe first lever arm has a pair of spaced-apart ears extendingtransversely therefrom between the handle portion and the clampingportion thereof. The spring clamp also includes an elongated slightlycurved second lever arm having a handle portion at one end thereof and aclamping portion at the other end thereof. A sleeve or pad embraces thehandle portion of the second lever arm. The length of the clampingportion of the second lever arm is shorter than the length of theclamping portion of the first lever arm.

The second lever arm has a pair of spaced-apart ears extending therefrombetween the handle portion and the clamping portion thereof. A pivot pinpivotally secures the ears of the first lever arm to the ears of thesecond lever arm whereby the lever arms may be moved betweenconventional clamping and non-clamping positions. A spring is mounted onthe pivot pin and engages the inner sides of the lever arms to yieldablyurge the lever arms to their clamping positions.

A spring clamp also includes an elongated pin, shaft or rod having aninner end and an outer end. The inner end of the elongated pin issecured to the clamping jaw of the second lever arm so that the pinextends outwardly therefrom in a generally parallel relationship to theclamping portion of the second lever arm. The pin of the second leverarm has a length whereby the outer end thereof will engage the inside ofthe pad or sleeve at the outer end of the clamping portion of the firstlever arm when the clamping portions are in the clamping position.

The traditional cabinet box or carcass 14 to which the face frame willbe attached has varying heights, widths and depths. The cabinet box willinitially be described as being in a vertically disposed position aswhen it is secured to a wall or the like. The cabinet box includes ahorizontally disposed upper wall member having a first end, a secondend, an inner end, an outer end, an outer surface and an inner surface.An opening is drilled in the outer surface of the upper wall memberwhich extends partially thereinto. The cabinet box also includes avertically disposed first side wall member having an upper end, a lowerend, an inner end, an outer end, an inner surface and an outer surface.The first side wall member has a plurality of spaced-apart openings orholes drilled therein which partially extend inwardly from the outersurface thereof inwardly of the outer edge thereof.

The cabinet box also includes a vertically disposed second side wallmember having an upper end, a lower end, an inner end, an outer end, aninner surface and an outer surface. The second side wall member has aplurality of spaced-apart openings or holes drilled therein whichpartially extend inwardly from the outer surface thereof inwardly of theouter end thereof.

The cabinet box also includes a horizontally disposed lower wall memberhaving a first end, a second end, an inner end, an outer end, an innersurface and an outer surface. At least one opening or hole is drilledinto the outer surface of the lower wall member which extends partiallythereinto.

The upper end of the first side wall member is secured to the first endof the upper wall member with the upper end of the second side wallmember being secured to the second end of the upper wall member. Thelower end of the first side wall member is secured to the first end ofthe lower wall member and the lower end of the second side wall memberis secured to the second end of the lower wall member.

The face frame which is to be attached to the cabinet box includes a toprail, a bottom rail, a first stile and a second stile. The face framemay include a mid-rail which extends between the first and secondstiles.

After the cabinet box has been assembled, the cabinet box will usuallybe placed on a horizontally disposed work surface so that the wallmembers of the cabinet box are vertically disposed with the inner endsthereof resting on the work support. Glue is then placed on the outerends of the wall members. The face frame is then positioned on the gluedouter ends of the wall members of the cabinet box. The spring clampsdisclosed above are then clamped into position. The handle portions ofthe lever arms are squeezed together against the force of the springincorporated therewith. The outer end of the spring of the spring clampof the clamping jaw of the spring clamp is inserted into one of theopenings formed in the outer surface of the side wall members with theclamping jaw of the first lever arm being positioned above one of therails or stiles of the face frame. The worker then permits the leverarms to move to their clamping position. The spring clamp clamps therail or stile of the face frame onto the cabinet box. Theabove-described steps are repeated for each of the spring clamps whichare used to clamp the face frame onto the outer ends of the cabinet box.

In those cabinet boxes having shelf adjustment holes on the innersurfaces of the side wall members, it is not necessary to drill theholes in the outer sides of the wall members. In that situation, thepins of the spring clamps are inserted into the shelf adjustmentopenings on the inner surfaces of the side wall members of the cabinetbox with the clamping portions thereof being positioned on the uppersurfaces of the stiles of the face frame to securely clamp the faceframe to the cabinet box during the gluing process.

A principal object of the invention is to provide an improved method andmeans for securing a face frame to a cabinet box.

A further object of the invention is to provide an improved method andmeans for securing a face frame to a cabinet box which eliminates theneed for nails, staples, pocket screws, splines, biscuits, tongue andgroove, dowels or bar clamps.

Yet another object of the invention is to provide an improved springclamp which enables a face frame to be glued onto the outer ends of thewall members of the cabinet box.

These and other objects will be apparent to those skilled in the art.

BRIEF DESCRIPTION OF THE DRAWINGS

Non-limiting and non-exhaustive embodiments of the present invention aredescribed with reference to the following figures, wherein likereference numerals refer to like parts throughout the various viewsunless otherwise specified.

FIG. 1 is a perspective view of one of the spring clamps which are usedin the attachment of a face frame onto a cabinet box according to themethod of this invention;

FIG. 2 is a side elevational view of the spring clamp of this invention;

FIG. 3 is an exploded perspective view of the cabinet box to which aface frame is to be secured;

FIG. 4 is an exploded perspective view of the cabinet box and face frameand which illustrates glue being applied to the outer ends of the wallmembers of the cabinet box;

FIG. 5 is an end sectional view illustrating the manner in which theface frame is clamped onto the outer ends of the side wall members ofthe cabinet box;

FIG. 6 is a partial perspective view illustrating the face frame beingclamped onto the outer ends of the first side wall member and the upperwall member;

FIG. 7 is a top elevational view illustrating the top rail, the bottomrail, the first stile and the second stile of the face frame beingclamped onto the outer ends of the wall members of the cabinet box;

FIG. 8 is an exploded perspective view of a face frame and a secondstyle of a cabinet box which illustrates glue being applied to the outerends of the cabinet box; and

FIG. 9 is a partial perspective view illustrating a pair of the springclamps of FIG. 1 being used to clamp the face frame onto the cabinet boxof FIG. 8.

DESCRIPTION OF THE PREFERRED EMBODIMENT

Embodiments are described more fully below with reference to theaccompanying figures, which form a part hereof and show, by way ofillustration, specific exemplary embodiments. These embodiments aredisclosed in sufficient detail to enable those skilled in the art topractice the invention. However, embodiments may be implemented in manydifferent forms and should not be construed as being limited to theembodiments set forth herein. The following detailed description is,therefore, not to be taken in a limiting sense in that the scope of thepresent invention is defined only by the appended claims.

The numeral 10 refers to a spring clamp, a plurality of which are usedto attach a face frame 12 to a face frame cabinet box or carcass 14 aswill be described in greater detail hereinafter. Spring clamp 10 issimilar to a spring clamp marketed by Menard, Inc. having a productnumber 249-1316. The spring clamp of Menard, Inc. is modified somewhatto enable the spring clamp to be used to clamp a face frame to thecabinet box or carcass.

Spring clamp 10 includes an elongated and generally slightly curvedfirst lever arm 16 having a handle portion 18 at one end thereof and aclamping portion 20 at the other end thereof. The first lever arm 16terminates in a clamping jaw 22. The clamping jaw 22 normally has a pador sleeve 24 thereon. Handle portion 18 normally has a sleeve 25 whichembraces the outer end thereof. The first lever arm 16 has a pair ofspaced-apart ears 26 and 28 extending transversely therefrom between thehandle portion 18 and the clamping portion 20 thereof.

Spring clamp 10 also includes an elongated slightly curved second leverarm 30 having a handle portion 32 at one end thereof and a clampingportion 34 at the other end thereof. Sleeve 35 embraces handle portion32. The second lever arm 30 terminates in a foreshortened clamping jaw36. As seen, the length of the clamping portion 34 of lever arm 30 isshorter than the length of clamping portion 20 of lever arm 30.

The second lever arm 30 has a pair of spaced-apart ears 38 and 40extending therefrom between the handle portion 32 and the clampingportion 34. A pivot pin 41 pivotally connects the ears 26 and 28 to theears 38 and 40 whereby the lever arms 16 and 30 may be moved betweenconventional clamping and non-clamping positions, as seen in FIG. 2. Aspring 42 is mounted on the pivot pin 41 and engages the inner sides oflever arms 16 and 30 to yieldably urge the lever arms 16 and 30 to theirclamping positions, as seen in FIG. 2.

The numeral 43 refers to an elongated pin, shaft or rod having an innerend 46 and an outer end 45. The inner end 44 of pin 43 is secured to theclamping jaw 36 so that pin 43 extends outwardly therefrom in agenerally parallel relationship to clamping portion 34. The pin 43 has alength whereby the outer end 45 of pin 43 will engage the inside of pador sleeve 22 at the outer end of the clamping portion of the first leverarm when the clamping portions 20 and 34 are in the clamping position ofFIG. 1. Preferably the pin 43 has serrations 46 on its outer surface.

The traditional cabinet box or carcass 14 will have varying heights,widths and depths. The cabinet box 14 will be described as being in itsvertically disposed position as when secured to a wall or the like.Cabinet box 14 will usually be constructed of wood, laminated wood orother material. Cabinet box 14 includes a horizontally disposed upperwall member 47 having a first end 48, a second end 50, an inner end 52,an outer end 54, an outer surface 56 and an inner surface 58. An openingor hole 59 is drilled in the outer surface 56 of upper wall member 47which extends partially thereinto. It is preferred that the hole 59 hasa diameter of approximately 5 mm. It is preferred that the hole 59 isspaced approximately 1.25 inches from the outer end 54.

Cabinet box 14 also includes a vertically disposed first side wallmember 60 having an upper end 62, a lower end 64, an inner end 66, anouter end 68, an inner surface 70 and an outer surface 72. Side wallmember 60 has a plurality of spaced-apart openings or holes 74 drilledtherein which partially extend inwardly from the outer surface 72inwardly of outer end 68. It is preferred that the holes 74 have atleast a diameter of 5 mm. It is preferred that the holes 74 be spacedapproximately 1.25 inches from outer end 68.

Cabinet box 14 also includes a vertically disposed second side wallmember 76 having an upper end 78, a lower end 80, an inner end 82, anouter end 84, an inner surface 86 and an outer surface 88. Side wallmember 76 has a plurality of spaced-apart openings or holes 90 drilledtherein which partially extend inwardly from the outer surface 88inwardly of outer end 84. It is preferred that the holes 90 have atleast a diameter of 5 mm. It is preferred that the holes 74 be spacedapproximately 1.25 inches from outer end 84.

Cabinet box 14 also includes a horizontally disposed lower wall member92 having a first end 94, a second end 96, an inner end 98, an outer end100, an inner surface 102 and an outer surface 104. At least one openingor hole 106 is drilled into the outer surface 104 of lower wall member92 which extends partially thereinto. It is preferred that the hole 106has at least a diameter of 5 mm. It is preferred that the hole 106 isspaced approximately 1.25 inches from outer end 100.

The upper end of side wall member 60 is secured to the first end 48 ofupper wall member 47 by screws 108 nails, staples or the like in atransverse manner. The upper end 78 of side wall member 76 is secured tothe second end 50 of upper wall member 47 by screws 110, nails, staplesor the like.

The lower end 64 of side wall member 60 is secured to the first end 94of lower wall member 92 by screws 112, nails, staples, or the like. Thelower end 80 of side wall member 76 is secured to the second end 96 oflower wall member 92 by screws 114, nails, staples, or the like.

The face frame 12 includes a top rail 116, a bottom rail 118, a firstside stile 120 and a second side stile 122. Face frame 12 may include amid-rail 124 which extends between stiles 120 and 122.

After the cabinet box 14 has been assembled, the cabinet box 14 willusually be placed on a horizontally disposed work support so that thewall members 47, 60, 76 and 92 are vertically disposed with the innerends thereof resting on the work support. Glue 126 is then placed on theouter ends 54, 68, 84 and 100 of wall members 47, 60, 76 and 92respectively. The face frame 12 is then positioned on the glued outerends of the wall members 47, 60, 76 and 92 as depicted in FIGS. 4 and 7and partially depicted in FIGS. 5 and 6. The spring clamps 10 are thenclamped into position as illustrated in FIGS. 5-7. Inasmuch as each ofthe spring clamps 10 are clamped onto the face frame 12 and the wallmembers of cabinet box 14, only one such clamping step will bedescribed. The handle portions 18 and 32 of lever arms 16 and 30 aresqueezed together against the force of the spring 42. The outer end 45of the pin 43 on clamping jaw 36 is inserted into one of the openings orholes 59, 74, 90 or 106 with the clamping jaw 22 of lever arm 16 beingpositioned above one of the rails or stiles of face frame 12. The workerthen permits the lever arms 16 and 30 to move to their clampingposition. Spring 42 clamps the rail or stile of face frame 12 onto thecabinet box 14. The serrations 46 on pin 43 serve to increase theconnection between the pin 43 and the respective wall member. Theabove-described steps are repeated for each of the spring clamps 10. Insome cases, it may not be necessary to utilize spring clamps on the topand bottom rails of the face frame although it is preferred to do so.When the glue has set, the clamps 10 are removed.

In those cabinet boxes having shelf adjustment holes on the innersurfaces of the side wall members, it may not be necessary to drill theholes 59, 74, 90 and 106. Such a case is illustrated in FIGS. 8 and 9wherein the cabinet box 14 has shelf adjustment holes 128 formed in theinner surface of side wall member 60 and shelf adjustment holes 130formed in the inner surface of side wall member 76. The pins 41 of thespring clamps 10 are inserted into the shelf adjustment holes 128 or 130to clamp the face frame 12 onto the cabinet box 14. In this case, it maybe necessary to drill holes in the inside surfaces of wall members 47and 92. The design of the spring clamp 10 allows the pressure of theclamp to be at the centerline of the glue line so as to not pull theface frame 12 out of alignment when the glue is in the wet stage.Further, the padded surface 25 of the lever arm 16 allows the face frameto be pre-finished prior to it being attached to the cabinet box.

If any of the clamp holes or openings must be hidden, plastic caps maybe inserted thereinto. A thin finish panel or veneer may also be appliedto the cabinet box at the finish ends thereof to hide the holes oropenings.

It can therefore be seen that a unique spring clamp has been provided tosecure a face frame to a cabinet box without nails, pocket screws,staples, etc.

Although the invention has been described in language that is specificto certain structures and methodological steps, it is to be understoodthat the invention defined in the appended claims is not necessarilylimited to the specific structures and/or steps described. Rather, thespecific aspects and steps are described as forms of implementing theclaimed invention. Since many embodiments of the invention can bepracticed without departing from the spirit and scope of the invention,the invention resides in the claims hereinafter appended.

I claim:
 1. A spring clamp, comprising: a first elongated lever armhaving a handle portion at one end thereof and a clamping portion at theother end thereof; said clamping portion of said first lever armterminating in a clamping jaw; said first lever arm having a pair ofspaced-apart ears extending therefrom between said handle portion andsaid clamping portion thereof; a second elongated lever arm having ahandle portion at one end thereof and a clamping portion at the otherend thereof; said clamping portion of said second lever arm terminatingin a clamping jaw; said second lever arm having a pair of spaced-apartears extending therefrom between said handle portion and said clampingportion thereof; a pivot pin pivotally securing said ears of said firstlever arm to said ears of said second lever arm whereby said lever armsare pivotally movable between clamping and non-clamping positions; saidclamping portion of said second lever arm having a length less than thelength of said clamping portion of said first lever arm; a springpositioned between said first and second lever arms which yieldablyurges said first and second lever arms towards their said clampingpositions; an elongated cylindrical pin having inner and outer ends;said inner end of said elongated cylindrical pin being secured to saidclamping jaw of said second lever arm so as to extend therefrom in agenerally parallel manner with respect to said clamping portion of saidsecond lever arm; said outer end of said elongated cylindrical pin beingin engagement with said clamping jaw of said first lever arm when saidlever arms are in their said clamping positions.
 2. The spring clamp ofclaim 1 wherein said elongated cylindrical pin has a serrated outersurface.